1009-Mechanical Design Criteria-Rev - Co

Doc.No.: R AND S /MECH/001.
R2 Date : 12th January 2011

Design Criteria: Mechanical Design Basis
1. GENERAL
The Conveyor System Package for coal handling facility as specified in technical specification for
coal in bulk for import at Adani Mormugao port Terminal Pvt. Ltd., Goa.
2. DESIGN CODESS
Code : CEMA (5th Edition)
Software used : AC-Tek, Sidewinder Plus v4.28
3. MATERIAL HANDLED
Material handled : Coal

: 0.8 t/m3 {for volumetric calculation }
Bulk Density
: 1.05 t/m3 {for stress on structure}
Moisture Content : 40% (Maximum)
Angle of Repose : 37 Degree
Angle of Surcharge : 20 Degree
Abrasiveness : Moderately Abrasive
Lump size : (-)100 mm Nominal, and (-) 150mm occasional
4. MATERIAL
Materials shall be of the following specifications or better:

o Cast Iron : IS 210, Grade 20; excepting counter weight.
o Cast Steel for gears : IS 2644, Grade 1.
Cast Steel for pressure pin assembly : IS 2644, Grade 4.
Cast Steel for general use : IS 1030-1978/2707-1973 – Grade 23 - 45.
o Wrought Steel : IS 1570, C40, Cold Drawn specified
o Forged Steel : IS 1875
o Structural Steel : IS 2062 Gr. B (Fusion welding quality)
o High Tensile Steel : IS 961 (Fusion welding quality)

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Doc.No.: R AND S /MECH/001.R2 Date : 12th January 2011
o Case Hardened Steel : IS 1570. C-14

o Ductile Iron : IS 1865, Grade 1
o Tubes & Fittings : IS: 1239, IS: 1161
o Tubes of Idlers : IS: 9295
o Gunmetal : IS: 306, G-2
o Phosphor Bronze : IS: 28
o Aluminum Bronze : IS: 305, Grade 2
o Stainless Steel : IS 6911
5. COMPONENTS
Items required to be manufactured/ fabricated for routine maintenance shall preferably conform to IS,
Code of Practice. The following is the list of items which shall be included but not be limited for such
considerations.
o Gears & pinions : Metric system

o Wire Rope : IS 2266
o Drum : IS 3177
o Wheels : IS 3177, IS 1136
o Sheaves : IS 3177
o Idler tubes/assembly : IS 9295/IS 8598
o Conveyor belting : IS 1891
Table 1-5 Mechanical Engineering Codes

Sr.No. Codes Descriptions
1 Federation Europeenne de la Rules for the design of Hoisting Appliances

Manutention (FEM)
2 BS-2573 Specifications for Permissible Stresses in Cranes and Design

Rules
3 Conveyor Equipment Manufacturer Belt Conveyors for Bulk Materials

Association (CEMA)
4 IS 11592 Selection & Design of Belt Conveyors
5 ASTM-D-2234 & ASTM-D-2013 Sampling

and ISO & JIS

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6 Fire Protection Manual (Tariff Fire Fighting system

Advisory Committee)
7 Specifications for Idlers & Idler Sets for Belt Conveyors

IS 8598
8 Steel Tubes for Idlers
IS 9295
9 Steel Wire Ropes for General Engineering Purposes –
IS 2266
Specifications
10 Code of Practice for Electric Overhead Traveling Cranes
IS 3177
and Gantry Cranes other than Steel Work Cranes
11 Preferred Sizes for Wrought Metal Products
IS 1136
12 Crane Rail Sections
IS 3443
13
IS 9295 Steel Tubes for Idlers for Belt Conveyors
14
IS 8598 Specification for Idlers and Idler Sets for Belt Conveyors
15
IS 1891 Conveyor and Elevator Textile Belting
16
ISO / Metric Screw Threads & Gearing Profiles
17 IS 210 Grade 20 excepting counter
Grey Iron Castings – Specification
weights
18
IS 2644 Grade 1 High Tensile Steel Castings
19
IS 2664 Grade 4 Specification for Quenching Oil
20
IS 1030 Carbon Steel Castings for General Engineering Purpose
21
IS 2707 Grade 23-45 Carbon Steel Castings for Surface Hardening
22 IS 1570, C40, Cold Drawn
Schedules for Wrought Steel
Specified
23
IS 1875 Carbon Steel Billets, Blooms, Slabs and Bars for Forgings
24
IS 276 Austenitic – Manganese Steel Castings
25 IS:2062
Hot rolled Low, Medium and High Tensile Structural Steel
(Fusion Welding Quality)
26 IS:961
Structural Steel (High Tensile)
(Fusion Welding Quality)

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27
IS 1570, C14 Schedules for Wrought Steels
28
IS 1895 Grade 1 Specification for Cotton New AR
29
IS 1239 Steel Tubes, Tubulars and Other Wrought Steel Fittings
30
IS 1161 Steel Tubes for Structural Purposes
31
IS 306 Grade 2 Tin Bronze Ingots and Castings
32
IS 28 Phosphor Bronze Ingots and Castings
33
IS 305 Grade 2 Specification for Aluminum Bronze Ingots and Castings
34
IS 6911 Stainless Steel Plate, Sheet and Strip
35 Design, Erection and Testing (Structural Portion) of Cranes &
IS 807
Hoists
36 Code of Practice for Design Loads for Buildings and
IS 875
Structures
6. CONVEYOR DESIGN
Conveyor design is based on the material to be handled considering its characteristics and rated
capacities required as per the final conveyor datasheet concluded with the client considering plot layout and
equipments functionality. All equipment including belt conveyors shall be designed and built to operate outdoor
at guaranteed rating capacity furnished in this specification considering continuous duty of 24hr/day, ambient
temperature of 50ºC and under climatic and ambient conditions existing at site.
Belt sag on the carrying side shall not exceed 2% of idler spacing. Maximum operating tension in the
belt shall not exceed eighty five (85) percent of maximum allowable working tension of the belt at the specified
load. Wrap angle shall be generally 210 ° for single snub drive pulley respectively. All drive pulleys shall be
lagged. Under all operating conditions including running, starting, fully or partially loaded or empty belt, the belt
shall not lift off the idlers. The radius of curvature shall be adequate so that there is no lift off of the belt in case
of Concave curve and no overstress at center of belt or lack of tension at belt edges in case of Convex curve. All
Conveyors shall be capable of starting fully loaded. Components of belt conveyors shall be standardized to the
extent possible viz. belting, pulleys, bearings, gearboxes and coupling to facilitate Interchangeability.

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6.1 FACTORS CONSIDERATION FOR DESIGN CRITERIA(CEMA 5th Edition)
Design influencing factors shall be referred / taken from the following detail & any other relevant criteria as
detailed in CEMA-5th edition.
6.1.1 K1 – Lump Adjustment Factor.
6.1.2 K2 – Effect of Load on bearing L10 Life
6.1.3 K3A - Effect of Belt Speed on predicted bearing L10 life

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6.1.4 K3B FACTOR
6.1.5 K4A - Effect of Maintenance on potential idler life

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6.1.6 K4B – Effect of environmental conditions on potential idler life
6.1.7 K4C - Effect of Operational Temperature on potential idler life

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6.1.8 Load rating for CEMA D idlers
6.1.9 Load rating for CEMA E idlers

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Doc.No.: R AND S /MECH/0001.R2 Date : 12th Jaanuary 2011
Design Criteria: Mechanical Desiign Basis
6.1.100 Kt – Ambieent Temperatu

ure correction factor
6.1.11 Kx – Idler friction

f factor

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6.1.12 Ky – Factor for calculating the force of belt and load flexure over the idlers

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6.1.13 Cw – Wrap factor
6.1.14 Cs – Skirt board friction factor

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6.1.15 Additional Belt Pull per Plow
6.1.16 Belt tension required to rotate Pulleys
6.1.17 Factors/ particulars affecting combined Drive unit Efficiency
Motor slip % : 2%
Coupling Slip % : 3%
Double Reduction Helical, Shaft mounted speed reducer : 0.970
Geared Coupling : 0.990
Pulley Bearing : 0.995
• Extra delayed filled chamber type fluid coupling selected for 22KW and above but less than 160 KW MNP
• Scoop Controlled Variable speed Fluid Coupling selected for 160KW and above MNP

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6.2 BELTINGS
Type : Nylon-Nylon (EOB)

Duty : Suitable for heavy duty application
Grade : M-24 Cover Grade
Construction : Cut edge
Belt covers : Synthetic Rubber
Belt joint : properly vulcanised and finished
Joint efficiency : Not be less than 80%
Belt Tension Ratio : 9 Min.
Cover thick. (Top/Bottom) : 5/3 mm
No. of plys : 4 nos. min.
6.3 IDLERS
Type : Garland, live shaft

Carrying idlers : 45 Deg. x 3 Equal rolls, inline
Return idlers : 15 Deg. x 2 Equal rolls (VEE type)
Impact idlers : Minimum 6 nos. x400mm spaced
Material : ERW tube
Mech. Prop. ERW tube : Equal YSt. 210 grade
Idler drag value : Shall not be more than 3.4 N/roll at 650 rpm,
20deg C as per DIN 22112
Bearing type/Make : Deep groove ball bearing with nylon cage of
SKF/FAG make
Bearing Life : L-10 of 60,000 hours minimum
Transition idlers : Minimum three nos. (20, 35 and 45 deg. resp.)
o Standard bracketed return idlers shall be provided in all inclined part of the conveyor.
o Flat return shall be provided under V-plows.
o All impact idlers shall have 5 roll type of size 100mmx80mmx80mm at pivot point.
o The self aligning troughing/return idlers shall be provided one each within 5m/10m resp. distance
from conveyors end.
6.4 PULLEYS
All pulleys shall have ring feeder / tapper lock assembly. These shall confirm to IS-1891/8531
Construction : Welded steel (M.S. IS: 2062)
Pulley shafts : Shall be EN-8 or equivalent
Shell thickness : 12 mm (Finished) for other pulleys & 16mm for drive pulleys.
Service factor (Bending) : 1.5 MIN.
Service factor (Torsion) : 1.0 MIN.

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Shaft deflection : Minimum 8 minutes (Non drive pulleys)

: Minimum 5 minutes (Drive pulleys)
• All drive pulleys / discharge pulleys shall have 16 mm thick herring bone grooved lagging at 120o,
6 mm wide x 6 mm deep spaced at 30 mm centers around the circumference. The apex of the
herringbone grooving should be in the direction of the belt travel. The rubber hardness shall be
IRHD 60.
• All non-drive pulleys shall have plain lagging of minimum 12 mm thick. The rubber hardness shall
be IRHD 45.
6.5 SKIRT BOARD
o All skirt boards are modular type skirt boards.
o 12 mm thick Skirt board with 12mm thick SS409M lined
o Length: Minimum five (5) times of belt width.
o Height of skirt plate shall be 900 mm.
o Inside Clear width between skirt boards shall be 2/3rd of belt width.
6.6 BELT TAKE-UPS
Each belt conveyor shall be provided with a gravity/Screw take-up. For horizontal gravity T.U.,
necessary sheaves shall be provided to reduce the movement of counter weight box. Counter weights shall be
made out of C.I / concrete with standardised denominations. In all cases space shall be provided for an addition
of 25% of the counter weight. Provision shall be made for dismantling the counter weight or relieving the tension
in the belt. Height of the take-up guide steel sections frame shall be sufficient to allow the take-up main pulley at
the time of belt jointing to get the required loop. For Gravity T.U device, Take-up travel shall be 2.5%+ 600mm
(minimum) for Conveyors with Nylon-Nylon belting.
6.7 GEAR BOX

Bevel-helical or helical gearbox with natural/fan cooled arrangement shall be used. Gearbox
mechanical power rating shall not be less than 1.55 times of the motor name plate rating (KW). Gear & pinions
shall be manufactured out of high tensile carbon/alloy steel, duly hardened and ground to withstand operating
conditions. Forged/Alloy Steel shafting to suit shall be provided with fabricated housing. The gear box
Mechanical power rating shall not be less than 1.85 times of the belt KW rating.

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6.8 COUPLING
All couplings shall provide for lateral, angular and longitudinal misalignment of shafts
Motor KW rating L.S. Coupling H.S. Coupling
KW< 22kw Geared type Pin bush type
22KW>KW< 160 KW Geared type Extra Delay Filled chamber type fluid coupling
160kw and above Geared type Actuator operated Scoop type fluid coupling(air cooled )
Dual drive Geared type Actuator operated Scoop type fluid coupling (air cooled
design)
6.9 BRAKES
Hydraulically operated thrusters brake or disc brake [mounted on brake drum coupling] shall be
provided.
6.10 BELT CLEANER/SCRAPER
Multi bladed Type [Sec Belt Cleaner]: A multi bladed (full belt width is made up of small
individual cleaners), having tungsten carbide blades mounted on a carrier assembly of steel tube shall be
provided. The steel tube shall be supported on both sides with elasto-mount or equivalent arrangement
having tensioning arrangement such that blade adjustment towards wear is automatic. The cleaner shall be
located in such a way that effective cleaning of belt is ensured and all scrapped material is lead into the
main chute. Separate dribble chute shall be provided, if required, so that there is no accumulation of
scrapped material on floor Qty: one (1) per Discharge pulley (located between discharge and snub pulley).
Primary Belt Cleaner: Construction of this type of cleaner shall be similar to Multibladed Type
cleaner but the blade-shall be made out of polyurethane material for such application. Qty: One (1) per
discharge pulley.
V plow type cleaner: This cleaner shall be made out of MS flats and polyurethane strips 20mm
thk (minimum) mounted suitably with the conveyor frame shall be provided Qty: 1 no on return side near tail
pulley + 1 no. on first bend pulley of GTU.
6.11 CHUTE
All Chutes & Hoppers shall be welded steel construction. The material of construction shall be as per
Data Sheet below.

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Location : As per flow diagram and Scope Work
Material of Hood above C.L. drive/ head pulley/ : 5 mm thk, MS (IS: 2062)
Material of parent plate : 12 mm thk, MS (IS: 2062)
Liner for Chute : 16 mm thickness, Manganese liner (grade

3 with 12% Mn content min.) of work
hardening properties. Liner to be bolted
with mother plate with counter shack bolt.
Each chute shall have adequate cross sectional area with minimum sloping angle of 60degrees or more to
ensure smooth flow of material. Belt loading chute shall be designed so as to ensure centralized loading of
material on the receiving belt to prevent off centre loading/excessive swaying of belt. Each chute shall be made
in a suitable number of units complete with matching flanges. These units shall be suitably bolt jointed. Each
joint shall be made dust leak proof by providing rubber gaskets. Dust tight-hinged inspection doors/bolted
removable covers/manhole covers at strategic locations shall be provided to facilitate inspection and to clear
jammed coal in the chute. Chute brackets shall be welded to the main plate and suitably anchored to the
floors/platforms in chute layout- inspection door, poking holes etc. shall be provided suitably and the discharge
chute shall enclose the snub pulley preferably. Otherwise separate dribble chute shall be provided (5mm thk,
MS, IS: 2062) below snub pulley so as to direct the scrapped material into the main chute. Where inline
magnetic separator is provided, chute made out of non magnetic material (parent plate) of minimum 8mm thk
SS-304 steel for a distance of 1.5m [minimum] from magnet face shall be provided. Adjustable baffle plates shall
be provide at the discharge of every transfer point. Curved deflector plate (Curved chute piece/ spoon) at chute
bottom shall be provided for each discharge chute. All chutes are properly designed for easy flow of material with
flow model analysis which ensures least acceleration of material and impact on receipt point with spoon feeding
at the bottom.
6.12 TRANSFRE TOWERS/ TOWERS AND DRIVE HOUSES

Size of transfer tower shall be subject to Consultant's approval. Working floors and equipment floors shall be
enclosed with suitable Color coated sheet of 0.6mm thickness, to ensure full protection from rain and strong
wind. Also claddings shall be designed to provide sufficient day lighting and ventilation. There shall be a
minimum 1.0 m wide clear walkway around drive equipment. Floor arrangement shall be such that free
movement for maintenance and operation purposes is provided. Suitable hatch openings shall be provided in
each floor for lowering/hoisting equipment or part of the equipment. All floor openings shall be protected by hand
-rails and kick (toe) plates. Monorails shall be provided at all towers/ transfer towers/drives houses for
maintenance of equipment. Monorails shall be equipped with manual hoists and transfer tower with height more
than 18mtr, also truck and wagon loading silo top floor shall be provided with electrical hoist having pendant
control. Ladder with an elevated platform shall be provided for maintenance of each hoist. All drive locations for
drive supporting structure should be casted in RCC.

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Manual or Electric hoist along with its monorail shall be provided as stated below:
• If unit load is equal to or more than 3tonne provide Electric hoist

• If lift for unit load is equal to or more than 18mtr provide Electric hoist
• If unit load is less than 3tonne and lift is less than 18m provide manual hoist
• For every inline magnetic separator, one (1) electric hoist with monorail shall be provided.
Capacity of hoist to suit the mass of Inline magnetic separator shall be provided.
• Monorail shall extend at least 2.0 m outside the tower/transfer tower/drive house.
• As far as practical all lifting tackles shall be standardized to the extent possible.
All other data of Electric and manual Hoist and monorail shall be as per technical specifications
7.0 Equipment Assemblies and Components
7.1 Wire Ropes
A. All wire ropes shall conform to IS: 2266. The tensile strength of the wire shall be 175-190 kgf/mm2
B. All wire ropes shall be preformed 6 x 19 or 6 x 37 IWRC, ordinary lay construction, unless
otherwise specified.
C. The fleet angle of the rope shall not exceed 1 in 12 for any relative position of the sheave/ drum
assemblies.
D. All wire rope terminations shall be made with solid forged thimbles and splices shall be mechanical
splices made with aluminum or copper ferrules.
E. Unless otherwise specified, factor of safety for wire ropes shall not be less than 6, based on the
nominal breaking strength and the working tension of the rope.
7.2 Wire Rope Sheaves
A. Wire rope sheaves shall be made of cast steel (IS: 1030, Grade -2) with grooved surfaces mounted
on antifriction bearings, groove surface to be hardened to 320 BHN (Min.)
B. The sheaves shall have machined grooves of uniform diameter accurately turned and finished
smooth and hardened after machining. The groove depth, contour, angle and radius shall be as per
recommendations in IS: 3177.
C. The diameter of the sheaves measured at the bottom of the groove shall be as per
recommendation in IS: 3177.
D. The sheaves/ pulleys shall be provided with proper lubrication arrangements.
E. (a) Equaliser sheaves shall have a minimum pitch diameter of 25 times of the rope diameter.

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E. (b) Running traversing sheaves-30 times of rope dia.
7.3 Shafts and Axles for Carriage
A. All shafts below 50 mm Ø shall be made of cold drawn steel. All shafts over 50 mm Ø shall be of
forged steel. Shafts shall be machined all over and the finish under the bearings shall be to the
degree and tolerance required by the bearing manufacturer. Generous fillets or long taper shall be
provided at each end of the swell.
B. Axles shall be of forged steel. In the case of design of shaft and axles based on strength, the
computed bending and torsional moments in the shaft or axle shall be multiplied by the load
service factors Km and Kt respectively.
Load Service Factors
Nature of Load Km Kt
a. Stationary Shafts & Axles:
Gradually applied loads 1.0 1.0
Suddenly applied loads 1.5 to 2.0 1.5 to 2.0
b. Rotating Shafts & Axles:
Gradually applied and steady 1.5 1.0
loads 1.5 to 2.0 1.0 to 1.5
Suddenly applied and minor 2.0 to 3.0 1.5 to 3.0
shocks loads
Suddenly applied and heavy
shock loads
C. In addition to designing shafts and axles for strength as specified above, shaft and axles shall be
checked for deflection as specified below:
a. The deflection of axles shall not exceed 1/1500 of the distance between bearing centres.
b. Shafts carrying cut tooth gearing shall be sized so that the relative slope of the two shafts
shall be limited to 0.0005 millimetre of face at the mesh.
7.4 Pins
A. All pins shall be of 16 Mn Cr 5 Steel. All pins subjected to wear due to rotation or oscillation shall
be case hardened, ground and polished. Surface hardness shall be minimum 55 RC and the depth
of case hardening 1 mm minimum.
B. The maximum permissible stresses in the design of pins shall be as follows:

Bending Stress 33% of Yield Stress

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Shear Stress 22.5% of Yield Stress

Bearing Stress 40% of Yield Stress
7.5 Fasteners and Keys
A. All gears, pinions, wheels, couplings, etc. subjected to torsion shall be keyed to the shafts using
parallel keys and keyways in accordance with IS: 2048. Idlers may be press fitted on the shafts.
Fits and tolerances shall be in accordance with IS: 919, IS: 210 and IS: 2709.
B. Set screws shall not be used for transmitting torsion but may be used for holding keys or light parts
in place.
C. Unless otherwise specified all holding down bolts and machinery bolts shall conform to IS: 1363 for
bolts of 6 to 39 mm dia and to IS: 3138 for all bolts larger than 39 mm.
D. Friction grip bolts shall conform to IS: 3757.
E. Plain washers conforming to IS: 2016 shall be used under bolt heads and nuts, whenever the
material is softer than the bolts themselves. Spring or lock washers shall be used throughout for
assembly of all machinery subject to vibration loads.
F. All bolts, nuts and washers shall be galvanized.
G. All fasteners for fixing drive components like motors, gearboxes and all Plummer blocks for all
pulleys shall be HT grade and shall be complete with plain washers, spring washers, nut locknut
etc.
7.6 Castings
A. All castings shall be sound and free from pin holes or imperfections. Outside surface shall be well
sand blasted and smooth. Critical castings shall be checked for internal flaws by x-ray or ultrasonic
methods.
B. All castings shall have well rounded corners and generous fillets to avoid stress concentrations. All
boss facings under bolt heads shall be machined.
C. Steel castings shall be stress relieved by suitable heat treatment.
7.7 Holes
A. All holes for fitting bolts and pins shall be drilled/ reamed. Flame cut or punched holes will not be
accepted.
B. Unless otherwise specified, clearance holes for metric bolts shall be as per IS: 1921
(medium)/1821.

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8.0 MOBILE HOPPER
The equipment shall consist of a hopper in Mild Steel construction which shall be supported on four (4)
corners by running gear. Four bogies shall be independently driven and shall run synchronized. The hopper
shall be of 9m x 8m (approx.) at the top with a suitable height. The hopper shall be supported by horizontal
built-up steel sections which in turn are supported on vertical columns. The entire unit shall be built with low
center of gravity so that the unit travels effortlessly. Suitable platforms and handrails shall be provided on
the main structure and near the top of the Hopper and at /near belt feeder platform. Suitable local control
panel shall be provided to control the various functions so that the Mobile Hopper/ belt feeder work smoothly
in conjunction with the Mobile Cranes & berth conveyor. The hopper/Belt feeder control should be
electrically interlocked with crane & conveyor control.
Technical Data:
a) Designation No. : MH-1 MH-2

b) Type : Self-Driven
c) Capacity of Hopper (each) : 100 tons of Coal (Live Capacity)
d) Qty : 1 no. 1 no.
e) Location : On Berth adjacent to Mobile Cranes (Grab type)
f) Material of Construction : Mild Steel (IS: 2062), 12mm thk Mother plate lined with SS-
409M Liner, 12mm thk (minimum). OR Ultrplate 3000
(10+5 mm)
g) Belt Feeder Details
i) Belt Width, mm (min) : 2000 x 20º Picking idlers 2000 x 20º Picking idlers
ii) Capacity, tph : 2000 (design) 2000 (design)
iii) Belt Speed, m/s : 0.7~0.1 0.7~0.1
iv) Skirt Board : As per spec. of conveyors. Continuous skirt board shall be
provided.
v) Other components : To confirm to requirement of as specified for belt
including Chute conveyors/ chutes.
H Rail span 13 mtr
I Top opening Min 9 mtr X 8 mtr
J Overall Height Max 14.5 mtr

K Drive VVVF drive shall be provided for belt feeder and long travel
application.

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L Rod gate Rod gate shall be provided at the bottom opening of

hopper. Weight of individual rod shall not be more than
16kg.
M Handrail Collapsible hand rail shall be provided at the top of hopper
along with platform on three side of hopper.
N Power supply CRD with stall start motor of full length travel shall be
provided along with hopper.
O Vibrator Electrical/ pneumatic vibrators are mounted on the hopper
structure to avoid the jamming of hopper. Hopper should
be designed in such a way that vibrator effect should
transfer to material. Required openings shall be provided in
the hopper body for manual inspection and pocking of
material.
P Bogie configuration Min 4 wheel/ corner of 630 dia shall be considered.
Bogie configuration shall be finalized in consultation with
client, to ensure the proper load distribution on jetty rail.
Q Other ancillaries Manual tie down and storm anchor shall be provided on the
hopper for the safety point of view during cyclonic
condition. All required details for interface part of jetty
construction for mounting of storm anchor and tie down
shall be provided by supplier. Also if embedded part is
required for mounting of above assembly than same are in
the scope of supplier.
S Electrical panel Electrical panel will be mounted on hopper with enclosure
to avoid the dust pollution problem. All required measure
shall be provided to avoid the dust pollution while handling
the coal through hopper.
Bogie drive shall have clutch mechanism which allows drives to disconnect when hopper is connected with
crane with the help of tie rod.
9.0 IN LINE MAGNETIC SEPERATOR
Magnetic separator shall be electro-magnetic type, with oil-cooled design. All equipment shall be totally
enclosed. Magnet Circuit comprising of insulated aluminum adequately impregnated with epoxy resin making it
impervious to moisture shall be provided. One Electric Hoist with monorail beam shall be provided suitable for
handling/ removal of magnetic separator for maintenance.
Each Magnetic Separator shall provide for continuous and automatic extraction and discharge of tramp metal

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(magnetic pieces) trough trump iron chute from coal mass on the respective belt conveyor.
The magnetic separator unit shall be mounted from structural member from the top. The required turnbuckle
arrangement to facilitate the necessary adjustments during operation shall be provided. The unit shall be
complete in all respects including all electrical ancillaries, viz. local control panel, ON/OFF control push buttons
and indicating lamps etc.
Dimensions and shape of the core and side poles shall be optimized to obtain wider, deeper field ensuring large
force index to effect higher lifting capacity over wide area.
Magnetic pieces picked by magnetic separator shall be discharged into tramp metal chute located suitably.
Suitable arrangement shall be provided in the magnet for keeping the coil of magnet dry from atmospheric
condition when the magnetic separator is not in use.
The other mechanical components of the Magnetic Separator like pulleys, bearing blocks, drive, belt etc. shall be
liberally designed to ensure trouble free operation. The motor and gear reduction unit for driving the belt shall be
adequately sized.
The separator belt shall be designed to withstand high temperature at the bottom of the magnet and also to
withstand impact of the sharp edges of the tramp iron pieces. The belt shall be provided with suitably spaced
built in ribs.
Each magnetic separator shall be suitable to lift the following tramp iron piece from the given belt.
MS cube of 20 mm size
250 mm x 250 mm x 50 kg. M.S. plate
MS round bar of 50 Kg with L/D ratio of 5(min)
MS Bolt of M12, M16, minimum length equal to 5 times the size
Shovel teeth & spikes.
Make: PBL / Eriz / ELECTROMAG .

Technical Data:
a) Type of Magnetic : In Line Magnetic Separator. Oil cooled type electromagnet with
Separator self-cleaning arrangement complete with local panel. Tramp
Metal collecting chute to be provided for each Magnetic
Separator.
b) Equipment Designation : ILMS-1 ILMS-2 ILMS-3
c) Location : As per Flow Scheme on Conv. # CR-1/CD-3/CRD-1
d) Conveyor Capacity (TPH) : 5000 2500 5000
e) Belt Width (mm) : 2000 1400 2000
f) Belt Speed (m/s) : 4.6 4.6 4.6
g) Troughing Angle : 45 45 45
(degrees)

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h) Operating Height : 450 mm

(approx.)
i) Flux Density (Minimum) : 1000 Gauss at operating height specified above
j) Force Index : 100000
k) Degree of Protection : IP 65
l) Magnet Core Material : Pure annealed iron/ eq. having high magnetic permeability, IS
4491
m) Coils : Cooper wounded coils with class “H” insulation
n) Rectifier : 3 ph., full wave bridge using Silicon Diodes forming rectifier set
o) Separator Belt : N/N Type of M-24Grade complete with built – in ribs and zero
speed switch. Geared motor drive shall be provided.
p) Wear plate of Stainless Steel SS-304 shall be provided at Electromagnet surface.
10.0 BELT WEIGHER
The belt -weigher shall consist of the carriage/ weighbridge assembly, belt speed sensor and the electronic
cabinet. The weighbridge shall be of multi idler system. Frictionless pivots-trunnion type suitably sealed
shall be provided which shall be impervious to vibration, moisture and material deposits. The weighbridge
shall be of rigid frame type having no moving parts and it shall maintain alignment permanently. It shall be
of unitized construction for quick and easy installation in the field.
The speed sensor mechanically connected to tail pulley/deflector roller shall provide a stream of pulses,
frequency of the pulse stream being proportional to belt speed. The Package (Integrator Unit) shall
provide the necessary intelligence to the system. The integrator receives the output signal from the
weighbridge & the speed sensor and adds them to the total on the Master Counter. Flow rate is displayed
by computation against a time base. The Integrator shall have feature such as automatic span and zero
calibration and self-diagnostics facility.
The digital speed sensor shall be packaged in rugged cast aluminum housing suitable for outdoor
installation. The speed-sensing element shall employ a brushless pulse generator producing a stream of
pulses, frequency of pulse stream being proportional to true belt speed. The pulse output is fed to the
Integrator Unit.
The Electronic Cabinet shall comprise of the Totaliser Rate Indicator etc .having microprocessor based
integrator. Total material weight, the material flow rate etc. shall be displayed on eight (8) digits LED. It
shall have facility such as Run/Set up/Lamp test/Auto zero/Auto Span/Enter etc. The Electronic Unit shall
have facility of digital processing, tantalization of data etc. And shall have bright easy to read digital display

Page 25

of flow rate of material and total tonnage passed etc. Electronic cabinet shall be rugged design with IP-55
degree of protection.
High precision load cell of strain gauge type or transducer fully temperature compensated shall be
provided. The accuracy shall be guaranteed within (±) 0.25 percent for all belt weighers except boom belt
weigher. All electronic equipment used shall be suitable for service in dust-laden atmosphere and shall be
actually tested, checked as per applicable standards to ensure continued reliability.
Belt Weigher Make shall be PBL/ AVERY/ ASEA/ IPA/ JENSION NICHOLSEN ENCARDIORITE/ Equal
approved.
Technical Data:-
Type of Belt Weigher : Electronic Load Cell Type, Microprocessor based
Designation No. : BS-1 BS-2 BS-3 BS-4
Number to be furnished : 1 1 1 1
Location : Conv. Conv. Conv. Conv.
# CR-2 # CD-3 # CD-6 #CD-7
Capacity of conveyor (tph) : 5000 2500 2500 5000
Weighing range : 20% to 120%
Belt width (mm) : 2000 1400 1400 2000
Belt speed (m/sec) : 4.6 4.6 4.6 4.6
Accuracy over full weighing Range : Within ± 0.25%
Totalizing Unit : To be Provided
Type : Eight digits, digital totalizer
Location : Control Room
Rate indicator : Both Local as well as remote to be provided
Type : Digital type
Location of display : • Local to be provided

• Remote at Control Room (on mimic panel) shall be
provided.

Page 26

Calibrating instruments as required : To be Provided
11.0 METAL DETECTOR

Search coil unit houses an oscillator coil and a receiver coil, Oscillator coil sets up
electromagnetic field which is concentrated in aperture of the search coil. In normal condition when
there is no tramp metal the receiver coil is so arranged that the output from it is extremely small.
When a tramp iron piece is passing through the coil, it disturbs the flux distribution and this induces
a voltage in the receiver coil. This voltage is then processed in the electronic unit and a DC voltage
proportional to the size and type of metal is obtained. This voltage is compared with a threshold
setting voltage which is used to set sensitivity of detection. When a metal of required size passes
through the coil a switching signal is available at the output of the above comparator, which drives a
monostable ckt. This monostable ckt actuates the relay for a fixed time and returns back after that
time. Thus a momentary change over contact is available from this relay. The contacts of this relay
are rated 5A/220V AC. Suitable spark suppression is also incorporated.
The metal detector shall operate on a principle that tramp metal causes a reaction in the
sensing device of the detector unit, in case, tramp metal passes through without being lifted, the
metal detector on sensing the tramp metal will activate the signal light and operate the sand marker
device to indicate location of metal piece and will also simultaneously stop the belt. The hook of the
sand bag marker is lowered by means of a relay contact. The sand bag is dropped on or near the
approx. location of the metal piece. Additional security circuit is provided so that the conveyor will
not start unless, the sand bag is put back again on hook of the marker.
Auto testing device checks the sensitivity of the metal detector at the interval of every 3 to 4
seconds and signal for malfunctioned/loss of sensitivity of the metal detector. Metal Detector Make:
POWER BUILD/ ELECTROMAG/ M.R.EQUIPMENT/ THERMORAMSEY/ equal approved.
a) Equipment Designation : MD-1 MD-2 MD-3 MD-3
b) Location : Conv#CR-2 Conv#CD-4 Conv#CR-6 Conv#CD-7
c) Quantity, no. : 1 1 1 1
d) Belt Width (mm) : 2000 1400 2000 2000
e) Capacity (TPH) : 5000 2500 5000 5000
f) Troughing Angle (deg.) : 45 45 45 45
g) Belt Speed(approx.), m/s : 4.6 4.6 4.6 4.6

Page 27

h) Search coil : 1No 1No 1No 1No
i) Electronic Cabinet : 1No 1No 1No 1No
j) Signal/Hooter : 1No 1No 1No 1No
k) Signal Lamp : 1No 1No 1No 1No
l) Material to be examined : (-) 150mm coal
m) Detector type and capacity : Electronic solid-state type, single channel suitable to detect
20mm dia. aluminium ball and MS nut of size M-20. Each
unit shall be complete with search coil, electronic cabinet,
signal lamp, signal horn, sand bag marker, and provision for
testing the unit.
n) Annunciation/Hooter : Yes
provided
o) Audible range of hooter : 300 m
p) Indication type : Audio and visual
q) Power supply : 230V±15%, 50 Hz±2%, Single phase, A C Supply
12.0 FIXED TRIPPER
The fixed belt tripper shall be provided on conveyors as per Flow Diagram.(Ref. : 1009-FS-L1-Rev. D)
The tripper shall have a sturdy, welded, structural frame and supports for mounting. A service platform shall be
provided on one side equipped with welded steel cross over platform with handrail and access ladders at each
end of the platform. It is located in front of and attached to the discharge chute.
Necessary guide rollers with bearings etc. shall be mounted on the tripper. Continuous deck plate shall be
provided below carrying idlers on trippers. Adequate radius of curvature shall be ensured to avoid any lifting of
belt. The tripper shall be designed to give trouble free operation at its guaranteed capacity.
Belt cleaners, Pulleys, Rollers, Idlers, etc. shall conform to the requirements as specified for belt conveyors.
Tripper head pulley shall be identical with drive pulley of conveyor in all respects. The other three (3) bend pulleys
(i.e. two (2) nos. on return side + one (1) no. on carrying side) shall also be identical in all respects.
The discharge chute of Fixed Tripper shall be connected to prism type diverter gate so that the material can be fed
either to the conveyor itself or to the conveyor located at floor just below the tripper floor.

Page 28

Technical Data:-
Type : Fixed type Tripper complete with rugged designed supporting

structure.
Location : As per Flow Diagram.
Designation no. & Qty : FT-1 & One (1)
Type/ Qty of belt cleaners required : Primary cleaner at discharge pulley of Tripper/ One (1) no.Plow
cleaner on bottommost bend pulley of Tripper/ One (1) no.
Conveyor capacity : 5000 TPH
Belt width (mm) : 2000
Type of discharge : Two-way discharge as noted above.
Material of chute & chute liners : Refer spec. for chute
Hinged inspection door on the chute : To be provided
Type of operation : Local as well as remote operation/control to be provided
Other Components : As specified for Belt Conveyors
13.0 TRAVELLING TRIPPER (TR-1/2)

• The traveling belt tripper shall be suitable for installation on Yard Conveyor CR-4 & CR-5. One (1) shuttle
conveyor shall be mounted below each tripper for formation of stockpile on either side of tripper
conveyor.
• The tripper shall have a sturdy, welded, structural steel frame and supports for mounting all the
machinery. A service platform shall be provided on one side. Tripper shall be equipped with welded steel
cross over platform with handrail and access ladder at each end of the platform. It shall be located in front
of and attached to the discharge chute. The tripper shall be mounted on two (2) sets of single flanged
cast steel wheels of hardened treads and fixed, type cold rolled steel axle. Antifriction bearings with
double labyrinth dust seals and easily accessible pressure gun lubrication fittings shall be provided.
Adequately sized rails with sturdy supporting structure shall be provided to cover the runway length.
Necessary guide rollers with bearings etc. shall be mounted on the tripper. Necessary idler wheels shall
be provided for smooth traveling of tripper.
• The C.G. of tripper shall be kept low so as to avoid “RUN-AWAY” condition of the tripper and to ensure
good stability for smooth operation of the tripper on full load.

Page 29

• Curvature of adequate radius shall be ensured on the tripper portion, so that conveyor belt will come in
contact with at least 50% of the idlers on the tripper portion on “No Load” condition and tripper at the
farthest position from the tail end of tripper conveyor.
• One belt cleaner at tripper head pulley, pulleys, rollers and idlers shall comply with the requirements
stated elsewhere in this specification. Tripper head pulley shall be identical with drive pulley of tripper
conveyor for its drum dia. & shaft dia.
• Tripper shall be suitable to operate at any desired position within the range of travel with positive
arrangement to ensure stoppage of travel.
• All grease fittings shall be accessible from the outside of the tripper, from the service platform.
• Limit switches provided at the ends to limit the travel of tripper, shall be of heavy duty type and
interlocked with drive of the tripper.
• The tripper shall have provision for dropping coal to shuttle conveyor. The rating of tripper travel motor
shall be adequate to move the tripper smoothly either in same or reverse direction to belt direction under
fully loaded conditions. Adhesive weight requirement and traction effort calculations shall be subject to
approval of Engineer/ Consultant.
• Motorized cable reeling drum and adequate length of trailing cables (power & control cable), push buttons
shall be supplied for each traveling tripper. Suitable cable tray minimum 300mm above floor level shall be
provided along the travel of the tripper for supporting and guiding the trailing cables.
• Fail safe AC thruster operated hydraulic brake of totally enclosed type shall be provided, which shall
engage as soon as tripper travel motor stops In addition to brake, tripper shall be provide with hand
operated rail clamps to hold it in any desired position.
• Suitable rail cleaners shall be provided on leading and trailing edge of tripper for each rail track.
• 3.15mm thk M.S deck plate continuous for full length of tripper shall be provided below carrying idlers.
• Tripper shall be designed to give a guaranteed capacity of 5000 tph. Drive equipment shall be suitable for
minimum sixty(60) starts/hr.
• For type and specification of drive motor, gear boxes and all other equipment associated with tripper,
relevant clauses of this specification shall be referred to.
• The axle should be directly coupled to drive unit through coupling. No chain/sprocket arrangement and/or
worm gear box shall be used for tripper travel drive unit.

Page 30

• Protection in the cable reeling mechanism shall be provided to avoid over tensioning & damage to trailing
cables. Over travel protection (limit) switches shall be provided on both ends of tripper travel Mechanical
stoppers with buffers shall be provided on rails to present over travel of tripper.
ix) Technical Data:-
a) Type Motor operated Traveling Tripper, Shuttle conveyor will

receive discharge from tripper to form stockpile#1/2
b) Location On Conveyor # CR-4 & CR-5
c) Qty. Two (2) [one for each conv. # CR-4/5],Designation no.TR-1/2
d) Type of drive unit for tripper Travel. Motor (reversible) coupled to bevel helical gear box coupled
to drive axle complete with couplings.
e) Rail size & gauge 90 lb/yard (minimum), gauge to suit
f) Length of rails To suit layout requirement
g) Type of belt cleaner required at tripper One (1) no. Primary and secondary cleaner at discharge
head pulley pulley (Refer spec. for conveyors)
h) Conveyor capacity 5000 TPH (rated), 5500 TPH ( Design)
i) Belt width (mm) 2000
j) Travel speed of Tripper Approx, ten (10) percent of conveyor belt speed
k) Type of discharge chute Suitable to feed shuttle conveyor.
l) Material of chute & chute liners To be provided as per specifications for chutes.
m) Hinged inspection door on the chute To be provided
n) Limit Switches Heavy duty type
o) Type of operation Both Local/ Remote operation to be provided
p) Cable reeling drum Type Stall torque motor type
q) Type of cable Composite Power and Control cable

Page 31

14.0 DIVERTER GATE WITH 2-WAY DISCHARGE CHUTE
Gate shall be used for diverting material flow from feed chute to any one of the spout way of 2-way
discharge chute. It shall be provided with a triangular shaped (prism) body housed in a M.S. fabricated housing with
feed/discharge flanges & structural section supports along with Rack & Pinion Type travelling mechanism with
geared motor drive. Drive unit shall be complete with reversible geared motor, coupling, etc.
The unit shall be provided with a 300φ hand wheel with chain for manual operation purpose. Two (2)
Inspection Doors (size: 300 mm x 400 mm approx.) shall be provided.
a) Diverter gate shall have adequate power to operate against the flow of material and under the
column of material.
b) As far as possible, all parts requiring lubrication to be sealed, lubricated for life type. Items which
require maintenance, and/or replacement shall be easily accessible and removable.
Slanting/sloping surface of gate shall be atleast at 580 to the horizontal for smooth flow of material.
Technical Data:-
1. Gate Body (Inner) : 10 mm thk M.S. (IS-2062) lined with 10mm

thk SS-409M liner of work hardening properties. .
2. Supporting Roller : Cast Steel life lubricated type.
3. Housing/Flanges/Base/Supports : M.S. Sections/Plate (IS: 2062)
Housing (outer body) made out of minimum 10 thk
M.S.
4. Rack & Pinion : M.S. fabricated Rack complete with two Nos. (2)
Alloy steel pinions. Shaft of EN-8, complete with
horizontal split type Plummer Blocks.
5. Hand Wheel/Chain : C.I. Hand wheel with link chain shall be provided.
15.0 MECHNICAL VIBRATING FEEDER
Mechanical vibrating feeders shall be provided under the free gravity flow hopper inside the conveyor tunnel below
stockpile. Total 8 nos. of vibrating feeder shall be provided as 4 nos. required on conv. CD-1 and other 4 nos. on
conv. CD-2.

Page 32

Technical Specifications:
Type : Heavy Duty Linear Motion, Mechanical Vibrating Feeder

Quantity required : 8 nos.
Feed material : Coal
Feed rate per hour : 1000 TPH each
Bulk density T/M3 : 0.8
` Moisture content % : 40% (Maximum)
Temperature °C : 50°C
Grain Size mm : 50 mm (assumed).
Duty : Below Hopper
Trough length mm : 3000
Trough width mm : 2000
Inclination Deg. : 12/15°
Motor requirement : 18.5 KW at 1000 rpm
16.0 WEIGH BRIDGE BASED TRUCK LOADING SYSTEM
Design Basis for Truck loading system:
1. Type of loading system : Weigh Bridge based In– Motion Truck Loading system to be installed
below the structural steel Silo, for simultaneous loading and weighing of
Coal in to different types of moving Trucks
2. No. of loading systems : Two systems
3. Number of Silo : 2 No
4. Material to be Loaded : Coal (-) 150 mm size approximate
5. Bulk Density of coal : 0.8 t / cu.mtr
7. No. of Loading Points : Two
8. Mode of Loading : Fully automatic weigh bridge Truck Loading system.
9. Rate of Truck Loading : 600 TPH
10. Truck Loading Speed : 1.5 to 2 Kmph
11. Loading time Per Truck : 40 Ton truck - 80 – 90 seconds at max.
: 10 Ton truck - 40 Seconds at max

Page 33

12. Type of Trucks to be Loaded : Different types of Truck/ Dumper
13. Truck Capacity : 10 Tons to 40 Tons
14. Truck scale Capacity : 80 Tons
15. Truck Scale Size : 24 M (L) * X 3 M (W)
16. Weighing accuracy : + 20 Kg of Truck scale capacity.
17. Loading Accuracy : +/ - 350 Kgs. of Target quantity.
18. Loading Schedule : 3 Shifts Power Supply

: 415 V AC, 75 HP 50Hz
* Based on the wheel center distances of TRUCK, Scale length might change a little.
TRUCK LOADING SYSTEM (System Description)
Truck loading system consists of sub assemblies like Emergency Gates, Swing chute, Hydraulic power pack, Truck
Scale, Traffic signal and dedicated loading controller, software, etc.
In feed conveyors, with will be filling the coal of size lesser than 150mm in to the Silo continuously.
Silo will have two out-let having a nominal size of 915 * 915 mm to have two Loading points.
Each load out will have One Emergency gate and One Swing Chute with Flow control gate. There will be a set of
complete hydraulic system with a complete set of electronics capable of operating the load out in Auto mode.
The sequence of operation is explained as follows. Beneath the outlet of Silo a Rolling single bladed slide gate
(Named as Emergency gate) will be mounted. Below emergency gate, Swing Chute Cum Flow Control Gate
assembly will be bolted
In case of a major hit with the chute by trucks , then the shear cum crushable section is provided at the bottom of the
chute will hive off from the chute, preventing any damage to the system or truck.
With the Help of DEDICATED CONTROLLER, Truck weighing Digitizer and various sensors the complete Automatic
Operation of loading & weighing is achieved with the help of the Specialized Load Control Software.
EMERGENCY GATE
Make : Merit
Quantity : 1 No / Silo
Size : 915 mm * 915mm (+/- 3mm)
Type : Hydraulic operated single bladed Rolling slide Gate.

Page 34

Actuation : Through hydraulic cylinder
A Rolling single bladed slide gate, having an opening of 915mm * 915 mm, operated by a single heavy duty hydraulic
cylinder will be fitted on the opening flanges at the bottom of the Silo. This gate blade will be made of 10mm mild
steel with a 16 mm plug welded abrasion resistant Manganese steel liner. This gate will be mounted on anti friction
rollers of needle type re-greasable Cam rollers. This gate will be used during emergency and maintenance of the
system. Proximity switches will be used for identifying the open or close position of Gate.
SWING CHUTE
Make : Merit
Size : 915mm * 915mm
Quantity : 1 No / Silo
The Swing Chute will have nominal size of 915 * 915 mm size opening, and this will be bolted at the bottom flange of
emergency gate.
10mm thick IS 2062 plate will be used as Chute Side walls, with 16mm thick manganese liner. This chute will swing
in the direction of the truck travel. The swinging action of the chute will ensure control over the positioning of chute.
Chute will have necessary replaceable Seals to minimize the dust. Chute will have a shear cum crushable section at
the lower part of the chute. In case of a Roll back by the truck or tall truck and, if the chute is not retracting in time
the shear section will get isolated from the chute. Chute will be activated by a single heavy duty hydraulic cylinder
which is cushioned at both the ends and operated with the help of a joystick from control room.
Proximity switches will also be used for identifying the position of swing chute.
FLOW CONTROL GATE

Make : Merit
Size : 915 * 915 mm
Quantity : 1 No
This gate will be located at the bottom of the above chute and will have a nominal 915 mm * 915 mm internal opening
and will be of proper non-jamming type design. It shall have the following specific features.
The gate wall shall be of 10mm thick mild steel plates with 16mm thick abrasion resistant manganese steel liner of
will be plug welded.
The gate blade shall be made of 16mm thick mild steel plate with 5mm thick type Stainless Steel top liner.
This shall pivot on a shaft supported by two flanged bearings with external lubricant fittings.

Page 35

Actuation of flow control gate shall be by two hydraulic cylinders.
The gate opening can be varied between fully close and fully open position. The gate position feedback will be taken
in to the DEDICATED CONTROLLER for controlling the flow of coal.
On the sides of the chute, skirt plate of soft rubber shall be provided to ensure that coal does not spill over the side of
the truck during loading operation.
The operation of the chute & gate has to be controlled from the DEDICATED CONTROLLER or from the console in
the proposed control room.
Proximity switches will also be used for identifying the open or close position of Gate.
HYDRAULIC SYSTEM:
Make : Merit
Quantity : 1 Set / Silo
Power pack will be mounted at the Power pack floor and it is designed to operate the following cylinders
1. Emergency gate - 2 Cylinder

2. Swing chute - 2 Cylinder
3. Flow control gate – 4 Cylinders
A complete set of hydraulic system will be provided for the loading operation. There will be a pump and motor, and
the power pack has to operate the hydraulic cylinders of various gate/chute. It shall be complete with shut off valves,
solenoid controlled directional valves, flow control valves, piping etc.
The hydraulic power pack shall consist of a Hydraulic oil Tank, fixed displacement vane type pump, unloading relief
valve assembly, filters set of accumulators and standard accessories like Level gauges, level switch, Filler Breather,
Temperature gauges etc.
A separate motor and pump assembly along with unloading relief valve assembly will be provided as
standby.
The complete system will be sized to provide sufficiently rapid action at all cylinders to achieve the required opening /
closing times. These timings must satisfy the fastest duty cycle, which is likely to occur when the material is in its
best state for flow and the truck is over speeding to the maximum tolerance allowed. Heavy duty welded type
construction hydraulic cylinders shall be well to operate the gates. Necessary high pressure hoses and ball valve
shall be provided to the cylinder lines.
A set of Hydraulic Accumulators will be used for the safety purposes and also to increase the speed of the operation
of the opening and closing of the gates. The accumulators will have sufficient capacity to close the Flow control gate
in the event of power failure and also to raise the chute to near Store position.

Page 36

The hydraulic system will have the following major components.
♦ 1 No Hydraulic Oil tank.

♦ 1 No of main pump of fixed displacement vane pump.
♦ Set of accumulator for high speed and failsafe operation.
♦ Set of hydraulic cylinders
♦ Reservoir capacity (Liters) – 200 Ltrs.( Approx)
♦ Pump capacity – 69LPM at 1500 RPM
♦ .Drive motors 25 HP, 1440 RPM
♦ 1 No standby pump of fixed displacement vane type
SYSTEM ELECTRONICS
Control system :
The following major components are envisaged in the control system to make it as a full automatic loading system.
1. Truck scale
2. DEDICATED CONTROLLER with control panel
3. Operator Desk
Truck Scale:
Make: MERIT
The Weigh scale will have 8 load cells of Shear beam type and the electronics will have in built self check, auto zero,
auto gain facilities and fault finding routings. The system is capable of operating at 230 V, 50 Hz, single phase
power, Junction boxes for termination of cables from load cells will be provided.
Design Basis:
Capacity : 80 TON
Type : Pit less
: Electronic weighbridge
Accuracy : +/- 20Kg of Scale capacity
No. Of Load cells : 8 No
Capacity of each load cell : 20 Tons
Dimensions of Plat Form :
Length : 24 M * ( Two sections of each 12 mtr )
Breadth : 3.10 M

Page 37

Height : 0.35 M
Material of construction : IS-2062
CONTROL EQUIPMENT
Control equipment for weighing and loading system shall comprise of
i) A Dual dedicated Micro processor based control unit for loading
ii) Dedicated Batch Weighing controller with highest complete conversions per second.
iii) PC based front End Software specially developed for loading system application.
iv) Printer to provide hard copy of the amounts loaded etc
v) Loading control console to permit manual, semi automatic operation of the loading system (one for
each loading station)
This equipment will be located in an air-conditioned control room beneath the silo at a suitable level to
provide good visibility of loading operation.
A dual redundant Based Control system ( back up for CPU and complete I/O ) Will be provided for semi/full
automatic control of the RLS.
CPU will receive all the inputs namely, limit switches, track switches, control desk inputs, hydraulic field inputs
through a set of 16 bit input modules. These inputs will be processed and through output module, Outputs will be
driven, namely, MCC, hydraulic system valves, operator control console etc. CPU will monitor all the inputs and
proper response will be initiated. CPU will also generate fail safe operation based on the inputs.
CONTROL DESK :
A touch screen based control desk shall be provided for the complete operation of Truck loading system
Loading Report & M.I.S Facilities:
Truck loading Report will be generated at the end of each truck loading, with Details like Truck In time , Number of
Truck , Tare weight , Amount of coal loaded for each Truck , and Truck out time, etc. The loading report will be
customized at the time of commissioning.
System will have 5000 Truck loading data or 3 months whichever is earlier. Also N” of loading report generation, shift
wise, weekly, monthly, M.I.S reports shall be possible.

Page 38

1009-Mechanical Design Criteria-Rev - Co

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1009-Mechanical Design Criteria-Rev - Co

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Doc.No.: R AND S /MECH/001.

R2 Date : 12th January 2011

Software used : AC-Tek, Sidewinder Plus v4.28

Material handled : Coal

Moisture Content : 40% (Maximum)

Angle of Repose : 37 Degree

Angle of Surcharge : 20 Degree

Abrasiveness : Moderately Abrasive

Lump size : (-)100 mm Nominal, and (-) 150mm occasional

Materials shall be of the following specifications or better:

o Case Hardened Steel : IS 1570. C-14

o Gears & pinions : Metric system

Table 1-5 Mechanical Engineering Codes

1 Federation Europeenne de la Rules for the design of Hoisting Appliances

2 BS-2573 Specifications for Permissible Stresses in Cranes and Design

3 Conveyor Equipment Manufacturer Belt Conveyors for Bulk Materials

4 IS 11592 Selection & Design of Belt Conveyors

5 ASTM-D-2234 & ASTM-D-2013 Sampling

Sr.No. Codes Descriptions

6 Fire Protection Manual (Tariff Fire Fighting system

7 Specifications for Idlers & Idler Sets for Belt Conveyors

Sr.No. Codes Descriptions

6.1 FACTORS CONSIDERATION FOR DESIGN CRITERIA(CEMA 5th Edition)

6.1.1 K1 – Lump Adjustment Factor.

6.1.2 K2 – Effect of Load on bearing L10 Life

6.1.3 K3A - Effect of Belt Speed on predicted bearing L10 life

6.1.4 K3B FACTOR

6.1.5 K4A - Effect of Maintenance on potential idler life

6.1.6 K4B – Effect of environmental conditions on potential idler life

6.1.7 K4C - Effect of Operational Temperature on potential idler life

6.1.8 Load rating for CEMA D idlers

6.1.9 Load rating for CEMA E idlers

6.1.100 Kt – Ambieent Temperatu

6.1.11 Kx – Idler friction

6.1.13 Cw – Wrap factor

6.1.14 Cs – Skirt board friction factor

6.1.15 Additional Belt Pull per Plow

6.1.16 Belt tension required to rotate Pulleys

6.1.17 Factors/ particulars affecting combined Drive unit Efficiency

Type : Nylon-Nylon (EOB)

Type : Garland, live shaft

Shaft deflection : Minimum 8 minutes (Non drive pulleys)

6.5 SKIRT BOARD

o All skirt boards are modular type skirt boards.

o 12 mm thick Skirt board with 12mm thick SS409M lined

o Length: Minimum five (5) times of belt width.

o Height of skirt plate shall be 900 mm.

6.6 BELT TAKE-UPS

6.7 GEAR BOX

KW< 22kw Geared type Pin bush type

6.10 BELT CLEANER/SCRAPER

Location : As per flow diagram and Scope Work

Material of parent plate : 12 mm thk, MS (IS: 2062)

Liner for Chute : 16 mm thickness, Manganese liner (grade

6.12 TRANSFRE TOWERS/ TOWERS AND DRIVE HOUSES

• If unit load is equal to or more than 3tonne provide Electric hoist

7.0 Equipment Assemblies and Components

7.1 Wire Ropes

7.2 Wire Rope Sheaves

E. (b) Running traversing sheaves-30 times of rope dia.

7.3 Shafts and Axles for Carriage

Load Service Factors

B. The maximum permissible stresses in the design of pins shall be as follows: